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- Draw current value stream (VS) map in terms of processes (or activities) OR use future map from previous cycle
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- Calculate times for current VS map
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- Analyze current VS map for waste (delays, additional inspections, extra motions, transport, search time, etc)
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- Make a list of relevant, comparable metrics (Cost of non-conformance, delays, search times, inspection times, quality levels, delivery times, customer feedback)
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- List opportunities for removing such waste by reducing, re-organizing, realigning, training
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- Select easiest opportunities to implement with highest impact first
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- Draw future map based on selected opportunities
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- Prepare action plan for selected opportunities
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- Implement plan by assigning tasks / due dates (no delays)
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- After implementation, let the system run and stabilize
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- Collect data again for measuring progress
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- Analyze data and compare against the “before” set of metrics listed under the Plan phase
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- Provide visuals (charts / figures) to show progress / improvement
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- Update future value stream (this will become the new “current” value stream)
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- List of things you’ve learned from this cycle? Implement in other areas and document for availability and easy access.
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- Goals achieved? If yes, What’s next on the opportunities list? If no, What’s the next goal?
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- Go the next cycle of PDCA
I’ll use an example in Part II.